United States
Environmental Protsction
Agency-
Office of Air Quality
Planning and Standards
Research Triangle Park NC 27711
EMB Report 31-MET-1C
June 1981
Air
Metallic Minerals
Visible Emission Test Report
Alurnax inc.
Mt. Holly Plant
Goose Creek, South Carolina
-------
VISIBLE EMISSION TEST REPORT
MT. HOLLY PLANT
ALUMAX OF SOUTH CAROLINA, INC.
GOOSE CREEK, SOUTH CAROLINA
by
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-3546
Work Assignment No. 2
PN 3530-2
Task Manager
Mr. Dennis Holzschuh
U.S. ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH, MD-13
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
June 1981
-------
TABLE OF CONTENTS
Page
1.0 Introduction 1-1
2.0 Summary of Results 2-1
3.0 Process Description 3-1
4.0 Test Procedures 4-1
Appendices
A Loading Facility Data Sheets A-l
B Unloading Facility Data Sheets B-l
C Project Participants C-l
D Observer's Certification D-l
E EPA Test Method 9 E-l
11
-------
1.0 INTRODUCTION
During the week of June 15, 1981, PEDCo Environmental per-
sonnel performed visible emission surveys on the Alumina loading
and unloading facilities located at the Mt. Holly Aluminum reduc-
tion plant, Alumax Aluminum Corporation, Goose Creek, South
Carolina. The purpose of the survey was to provide emission data
to support the New Source Performance Standards (NSPS) for metal-
lic mineral processing plants.
This report consists of a summary of visible emission re-
sults, brief process description, test procedure, and appendices
containing a list of project participants, and field data sheets.
During the survey a representative of the NSPS contractor
was on site to monitor process operations and record pertinent
information. Process data are used to evaluate the representa-
tiveness of emissions and to compare emissions to specific
process occurrences. The process description in Section 3.0 of
this report was prepared by TRW.
1-1
-------
2.0 SUMMARY OF RESULTS
Visible emission surveys were conducted at the Mt. Holly
Aluminum plant, loading and unloading facilities by two certified
observers. Table 1 provides a summary of results for the loading
facility and Table 2 summarizes results for the unloading facil-
ity. Copies of the field data sheets appear in Appendix A and B.
A total of 60 six-minute sets were recorded at the loading
facility. 30 six-minute sets evaluated fugitive emissions at the
rail car loading points and 30 six-minute sets evaluated emis-
sions from the baghouse controlling emissions from the transfer
system. The highest set averaged 4 percent opacity at the rail-
car loading points with an average opacity of 1 percent for the
30 sets. All readings were 0 percent opacity at the transfer
system baghouse.
A total of 120 six-minute sets were recorded at the unload-
ing facility. 30 six-minute sets evaluated fugitive emis-
sions at the railcar unloading points, 60 six-minute sets eval-
uated fugitive emissions leaving the unloading facility and 30
six-minute sets evaluated emissions from the transfer system
baghouse. The highest set averaged 14 percent opacity at the
railcar unloading points with an average opacity of 3.4 percent
for the 30 sets. The highest set averaged 5 percent opacity for
2-1
-------
TABLE 1. SUMMARY OF VISIBLE EMISSIONS AT LOADING FACILITY
Source
Fugitives
Baghouse
Number of
six-minute
sets
30
30
Range of
readings,
% opacity
0 - 5
0
Range of
six-minute set
averages, % opacity
0 - 4
0
Average
opacity,
%
1
0
2-2
-------
TABLE 2. SUMMARY OF VISIBLE EMISSIONS AT UNLOADING FACILITY
Source
Fugitives at
unloading
point
Fugitives
leaving
building
Baghouse
Number of
six-minute
sets
30
60
30
Range of
readings,
% opacity
0 - 40
0 - 15
0
Range of
six-minute set
averages, % opacity
0-14
0 - 5
0
Average
opacity,
%
3.4
2
0
2-3
-------
fugitives leaving the unloading facility with an average opacity
of 2 percent. All readings were 0 percent opacity at the trans-
fer system baghouse.
2-4
-------
3.0 PROCESS DESCRIPTION
Alumax is the most recently constructed primary aluminum
reduction plant in the country. Startup of this plant was mid-
1980. Alumina is shipped to Charleston harbor from Australia via
ships under contract from various companies. Alumina is unloaded
from open holds with a vacuum unloading system designed by
Alusuisse. Alumina is then transported by air slide and conveyor
belt to large storage tanks.
Railcars are loaded at the dock area in a covered shed
approximately 90 feet long and open on two sides. Alumina is
conveyed to a hopper above the railcars and dropped through a
system of telescoping chutes into the railcars. Two railcars can
be loaded simultaneously through parallel loading systems. Each
railcar is loaded through three chutes. These chutes fit tightly
into hatches on the top of the railcar. Displaced air is drawn
from the railcar through three smaller telescoping chutes and
ducted to a baghouse. Specifications on this baghouse are as
follows:
Manufacturer: Flex-Kleen (Research-Cottrell)
Model: 100-WRC-160-IIIG
Air flow rate: 11,000 cfm
Air-to-cloth ratio: 5.7 to 1
Cleaning mechanism: pulse jet
Bag material: 16 oz. singed polyester
3-1
-------
Once in position, a railcar can be loaded in 15 to 25 minutes
depending on the level of material in the loading hopper.
From the dock area the cars travel approximately 14 miles to
the primary reduction facility. The unloading operation is
enclosed in a shed approximately 100 feet long and open at both
ends. Alumina is unloaded from the car by gravity feed through a
grate into two hoppers. Each hopper has two screw conveyors
which feed material to a larger screw conveyor and from there to
a belt conveyor. The only air exhaust at the unloading station
is located at the transfer point between the screw and belt
conveyors.
Railcars are unloaded individually. After being positioned
over the hopper grate, three bottom slide hatches on a railcar
are opened. During the period of time during which the alumina
is filling up the hoppers, fugitive emissions are noticeable
inside the building. These emissions are apparent for 3 to 6
minutes depending on the extent to which the material in the
hoppers has been drawn down and the sequence in which the hatches
are opened. Eventually alumina mounds up to the bottom of the
railcar hatches. The rate of feed from the railcar then becomes
controlled by removal of alumina from the hopper by the screw
conveyors. With the free fall zone of alumina minimized, the
fugitive emissions are virtually eliminated for the remainder of
the unloading period (approximately 30 minutes). Minor fugitive
emissions may occur during the closing of the railcar slide
hatches.
3-2
-------
Specifications on the baghouse collecting emissions at the
railcar unloading facility are as follows:
Manufacturer: Flex-Kleen (Research-Cottrell)
Model: 84-WUDC-32-III
Air flow: 1300 cfm
Air-to-cloth ratio: 4.06 to 1
Cleaning mechanism: pulse jet
Bag material: 16 oz. singed polyester
3-3
-------
4.0 TEST PROCEDURES
All opacity measurements were recorded according to EPA
Method 9 procedures by two certified observers. Three one-hour
tests were conducted at each source identified at each facility.
During each test, data were taken at fifteen second intervals.
At the end of each one-hour test the observers received a ten
minute break to prevent eye fatigue. One observer was assigned
to the baghouse at each facility and the other observer read
fugitive emissions at each facility. The position of the obser-
vers and a diagram of the points of emissions appears in Figures
4-1 through 4-5. Special precautions were taken to ensure that
observers were properly positioned with respect to the sun angle
and the plume where applicable. Copies of the observer's certi-
fication appear in Appendix D.
4-1
-------
RAIL CAR
Figure 4-1. Loading facility fugitive site.
4-2
-------
OUTLET
*
30'
BAGHOUSE
30'
GROUND
TRAIN LOADING AREA
® OBSERVER
Figure 4-2. Loading facility baghouse outlet.
4-3
-------
OBSERVER
Figure 4-3. Unloading facility fugitive site.
4-4
-------
Figure 4-4. Unloading facility site for fugitive emissions
leaving building.
4-5
-------
BUILDING
BAGHOUSE
INLET \
I.D. FAN
OUTLET
*
3'
T
15'
GROUND
Figure 4-5. Unloading facility baghouse outlet.
4-6
-------
APPENDIX A
LOADING FACILITY DATA SHEETS
A-l
-------
RECORD OF VISUAL DETERMINATION OF OPACITY
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(check 1f applicable)
Attached
Detached
COMMENTS
clrfle^ raist&cL
/?/#Af ff/ie/e_,
7
cJwfe.* faise^1
\ e
-------
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE / OF 3
COMPANY y^/l^fcL
LOCATION CA*A/&^ . ;£ c.
TEST NO. ^<- - /
DATE <>'/<,•&
TYPE FACILITY ^/if^^^a £oaJ.>»^. /7^/v)
CONTROL DEVICE R Active- A,
^ ^le-fSkf
OBSERVER CERTIFICATION DATE /^^// ^ . /?J//
OBSERVER AFFILIATION ?
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POINT OF EMISSIONS U^J/^t /^?x?/v^ TLtafa*.**. ^L-r/er
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0
0
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The source'was/was not In compliance with
at the time evaluation was made.
-------
-------
COMPANY .
LOCATION
TEST NO.
DATE
f,C.
AC - I
OBSERVATION RECORD
OBSERVER
PAGE 3L OF
TYPE FACILITY
POINT OF PUSS IONS
Hr.
/(•
/£
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/*
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//
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to
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o
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0
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o
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0
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o
o
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
* .
A-12
-------
COMPANY /?/u/nA.V.
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
, OBSERVER 7)
YPE FACILITY
POINT OF PUSS IONS
PAGE B OF 3
Hr.
/I?
/7
Min.
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
A-13
-------
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE / OF 3
COMPANY ftfu^A^L
LOCATION CW/ta-fox) &.C.
TEST NO. riS-JL '
r- DATE I,. /?••?(
TYPE FACILITY //^J^w ;/*«//>** /^v)
CONTROL DEVICE ff/t^^ eJ^ ' £**/.
POINT OF EMISSIONS C*AJ,»* /TXAM) ftte£>"Sc, O^-rl&T
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/^cT^» */7 ^/
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/7t>$ ~//(^
/!/
-------
9*
-------
COMPANY
LOCATION
TEST NO.
DATE
S.C.
OBSERVATION RECORD
OBSERVER
PAGE _£, OF J
TYPE FACILITY
POINT OF EM I SS I ONS
_
Hr.
A
.
Min.
X*
£/
2*
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
5^7Ar-€A4
y
tf/tW/ 7%/9,fr3
£>4sS.}tr+
-------
COMPANY _
LOCATION
TEST NO.
DATE b-17'tl
OBSERVATION RECORD
OBSERVER
TYPE FACILITY
PAGE _J OF 3
POINT OF EMISSIONS
Hr.
H
/?
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ff
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0
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
A-16
-------
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE JT OF $_
COMPANY >*/.^,y,rf<_
LOCATION &J*/emJ , 'S.C,
TEST NO. AL- -3
DATE . L>*-/7*Sl
TYPE FACILITY Al*+i/*A UtJ.^ /TJUI,M)
CONTROL DEVICE Rpcl »^t. ^
CLOCK TIME
OBSERVER LOCATION
Distance to Discharge
Direction from Discharge
Height of Observation Point
BACKGROUND DESCRIPTION
HEATHER CONDITIONS
Wind Direction
Hind Speed
A*b1ent Temperature
SKY CONDITIONS (clear, over-
cast, X clouds, etc.)
PLUME DESCRIPTION ****'
Color
Distance Visible
OTHER INFORMATION
Initial
/7*o
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fit*
6*.*J
12/Ls*
//k/
^-/S*
1t>
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e/««
HOURS OF OBSERVATION /
OBSERVER 3/W
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OBSERVER CERTIFICATION DATE >fa,7 2 / /f//
OBSERVER AFFILIATION /
p&^* e^t/,
POINT OF EMISSIONS /?Ac/ *+at rtu.i/*.T
HEIGHT OF DISCHARGE POINT(
Final
/fjjt-
lOs'l
//***
&*«**
^P^BftM
I** W
f
&/f
£2 /)
fr/1
-------
96
-------
COMPANY
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE 0L OF
. C,
TYPE FACILITY
POINT OF EMISSIONS
Hr.
/7
Min.
^5"
Zt
37
if
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
A-18
-------
COMPANY
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE ^2_ OF ^
TYPE FACILITY
POINT OF EMISSIONS
Hr.
/7
I*
Min.
^r
5~L
2 /
"2 "2-
X3
P/
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0
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
•
A-19
-------
APPENDIX B
UNLOADING FACILITY DATA SHEETS
B-l
-------
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE / OF
COMPANY HLjsrtoX HLn^/AJuttts
LOCATION £L*rLe$J-,**j . I7j *fft /
TVOr FAT II ITV /!X.l v7/
Ifrl PMblLIIT rr/ fine*. f*4 f7/ w wQtsm^fpf
CONTROL DEVICE
CLOCK TIME
OBSERVER LOCATION
Distance to Discharge
' Direction fron Discharge
03
10 Height of Observation Point
BACKGROUND DESCRIPTION
WEATHER CONDITIONS
Wind Direction
Mind Speed
Aablmt Temperature
SKY CONDITIONS (clear, over-
.cast, X clouds, etc.)
PLUME DESCRIPTION ****'
Color
Distance Visible
OTHER INFORMATION
Initial
1 ! I 2-
r( &
£*$/
^- round
SArf
h/
&— S
^7^/r
tf/.^
/2L-
OBSERVER CERTIFICATION DATE 4n*t'L 2,/lG/
OBSERVER AFFILIATION P&
POINT OF EMISSIONS JVe>^
HEIGHT OF DISCHARGE POINT
Final
/Cf/z.
zo-
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6-^^
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257
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SUMMARY OF AVERAGE OPACITY
Set
Number
/
2-
3
^
5"
(,
7
£
CV
/O
Time
Start-End
01I1-&J/7
ttflb -012*3
69/4-0729
0750 -
-------
-------
COMPANY .
LOCATION
TEST NO.
DATE
1-7
OBSERVATION RECORD
OBSERVER TT C/
PAGE
/e
OF
TYPE FACILITY
POINT OF EH I SS I ONS ti
Hr.
flr/
«f
0<*
01
0^
Min.
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27
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4°
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STEAM PLUME
(check 1f applicable)
Attached
Detached
">
/
COMMENTS
c.«w /v&Ji"*}
V
>«Ckjie$ *f>/>e4J/V?«»
r
B-3
-------
COMPANY _
LOCATION
TEST NO. j}LiL -4 Ef
DATE " '
OBSERVATION RECORD
OBSERVER
PAGE 3 OF _j_
TYPE FACILITY
POINT OF EMISSIONS
17
Hr.
Ift
0°(
0^
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in
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42.
4 7
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B-4
-------
f-.-
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE
OF
COMPANY Ai* oocty /fc-*v,/on +»^
LOCATION Ghif/ffpAfAJ. SC
TEST NO. dUL -£/?
DATE 3"ufr>/>, | 7; /9£ /
TYPE FACILITY r /vrr*»j-y J0l>*iisy)/'/Ucssri
CONTROL DEVICE
CLOCK TIME
OBSERVER LOCATION
Distance to Discharge
w Direction from Discharge
Height of Observation Point
BACKGROUND DESCRIPTION
WEATHER CONDITIONS
Wind Direction
Wind Speed
Ambient Temperature
SKY CONDITIONS (clear, over-
.cast, I clouds, etc.)
PLUME DESCRIPTION ****'
Color
Distance Visible
OTHER INFORMATION
Initial
/O.-JV
to'
HE-
G,o»»4
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3-%
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HOURS OF OBSERVATION jQ; Z V —
OBSERVER The
< & s*s ~ ^
OBSERVER CERTIFICATION DATE 4f>r/l*£f/7a/
OBSERVER AFFILIATION p£ frcJ £~*J v J r*>* **,*,+*>**, £,
POINT OF EMISSIONS /v/W/u»s Le. Kfe/»
HEIGHT OF DISCHARGE POINT
Final
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to'
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5 - *Ja'
SUMMARY OF AVERAGE OPACITY
Set
Number
/
Z
3
4
5
^
7
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10
Time
Start-End
/WZ9
A>*0 -/^55
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/O^A~//O 7
ins -no°i
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///^» - //^ /
//^z- //27
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Opactlty
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O
(9
0
0
0
o
o
0
o
o
Average
O
^
2>
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O
O
O
O
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Readings ranged from O to T> X opacl
The source was/was not In compliance with
at the time evaluation was made.
fi*oe*S
c/^^^^/^W-///^*-
ty
-------
-------
COMPANY _
LOCATION
TEST NO. AUL-
DATE
OBSERVATION RECORD
OBSERVER T^/??
PAGE n2 OF 3
TYPE FACILITY Prtwrt*
POINT OF D11SSIONS
17
Hr.
10
lO
ID
1&
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Min.
2 4-
Z c,
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77
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15
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o
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0
0
o
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9
0
O
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6
STEAM PLUME
(check 1f applicable)
Attached
Detached
W
COMMENTS
Clrmtipg ipf.'sr-, r*S>s*r<'~.'\' •
1 T
PrcrCZ^ cl~.-+'
-------
COMPANY _AL
OBSERVATION RECORD
OBSERVER Torn
PAGE
& f<.
LOCATION
TEST NO.
DATE T
TYPE FACILITY
POINT OF Et1I SS I ONS
/'/ ,4 « :
Hr.
Min.
Seconds
15
30
45
STEAM PLUME
(check 1f applicable)
Attached
Detached
C?
o
(7
/z
o
(0
l u
O
1 7
0
70
II
Z 2-
o
o
o
0
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2.9
o
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li
O
B-7
-------
09
I
00
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE / OF 3
COMPANY flL*Arr»c*x /JLu*Y>j*j^iJr7si* HOURS OF OBSERVATION iHJTO — Id. ' 60
LOCAT ION <*k* r lt> < nC-^j
<^«*
*~t
'10*
OBSERVER *n«>Kr7c»s &'{*/*• &fc
OBSERVER CERTIFICATION DATE jfss/t 2, /<*& /
OBSERVER AFFILIATION p£
POINT OF EMISSIONS A"7'i
HEIGHT OF DISCHARGE POINT
Final
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to'
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&M>«J
3/^*1.
|\)
VI
on?=
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fr^o*
>«>/
^rVe5 6s«»f//^ 6V«»^
/ '
SUMMARY OF AVERAGE OPACITY
Set
Number
/
2.
3
4
5
£
7
£
f\
/P
Time
Start-End
////O - //55
//^ • /2^> /
/A*3-/Z6'7
IZO& -/*>/£
Ul^-/^l°f
1320-122$
l*2b ~IZ$I
I23Z -1257
I2Z& -1243
/St4+-f2.4=l
Opactlty
Sum
^
O
O
0
O
5
0
0
O
0
Average
£
O
O
O
O
£>. 2_
O
O
0
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TEST NO. A ML - (*>
DATE "3 u A)g / "7,
OBSERVATION RECORD
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COMPANY
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TEST NO. fi\AL~
DATE
OBSERVATION RECORD
OBSERVER
PAGE _J OF
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RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE / OF
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COMPANY .
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TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE ^ OF 3
TYPE FACILITY
POINT OF EMISSIONS
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RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE / OF 3
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TEST NO. AUL - /
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DATE "3"* 10 g > (; i /Q ft /
OBSERVATION RECORD
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COMPANY AL a
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RECORD OF VISUAL DETERMINATION OF OPACITY
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CONTROL DEVICE
CLOCK TIME
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-------
COMPANY
LOCATION
TEST NO. AuL - 2,
DATE r
OBSERVATION RECORD
»,*,, OBSERVER T>
TYPE FACILITY
POINT OF EMISSIONS
PAGE
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B-18
-------
COMPANY 4
LOCATION
TEST NO.
DATE
flL.
OBSERVATION RECORD
OBSERVER
PAGE 5 OF 3
TYPE FACILITY p>rJ««o
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B-19
-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE /
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TEST NO. ,^/.$ * /
DATE £ • /£ ',/"/
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LOCATION
TEST NO.
DATE
OBSERVATION RECORD
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PAGE 3, OF 3
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COMMENTS
B-21
-------
COMPANY
LOCATION
OBSERVATION RECORD
OBSERVER
FACILITY
PAGE 3
TEST NO. /ft/lfl -f
DATE fe V
POINT OF EMISSIONS
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Attached
Detached
COMMENTS
B-22
-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE
0
to
COMPANY fi/wA*.
LOCATION GA*g)«jTb^ X.C,
TEST NO. AfLp -Z '
DATE (o'/L'X)
TYPE FACILITY x^^i/^ Mo/eAt/fr?
CONTROL DEVICE fi*J ,^ £/
OBSERVER CERTIFICATION DATE ^v?;/ ^/ /f//
OBSERVER AFFILIATION /
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POINT OF EMISSIONS fa/^Jus /?/&t*v**. ro««±
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SUMMARY OF AVERAGE OPACITY
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0
0
0
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Readings ranged from O to ft X opacl
The source was/was not in compliance with
at the time evaluation was made.
ty
-------
-------
COMPANY
LOCATION
TEST NO.
DATE
-JUL& -
OBSERVATION RECORD
OBSERVER
TYPE FACILITY
POINT OF
PAGE _
10
1*
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STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
B-24
-------
me*,
COMPANY <
LOCATION
TEST NO.
DATE (P//I./G/
e -
OBSERVATION RECORD
OBSERVER otj
TYPE FACILITY
PAGE
OF
POINT OF EMISSIONS &a*/,0af<* 0esS*?/f
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(check if applicable)
Attached
Detached
COMMENTS
B-25
-------
RECORD OF VISUAL DETERMINATION OF OPACITY PAGE / OF ^
COMPANY 41 **/)*
LOCATION cfa£./e.*r&jJ 3, C,
TEST NO. >^<-£-j
DATE (.a*
&/M&1
/V/U/
3'^
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>'/LA0~
tdeAt-
'
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SUMMARY OF AVERAGE OPACITY
Set
Number
/
2
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if.
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4
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O
0
O
0
6
O
0
O
0
O
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0
O
^
O
o
o
0
6
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Readings ranged from O to O I opacity
The source was/was not In compliance with
at the time evaluation was made.
-------
9?
$1**
*»* ********
my
9*
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r#£
-------
COMPANY
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE x? OF
TYPE FACILITY
POINT OF EMISSIONS
Hr.
//
//
//
//
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//
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0
0
0
6
t>
STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
B-27
-------
COMPANY A
LOCATION
TEST NO.
DATE
OBSERVATION RECORD PAGE J1 OF 3
OBSERVER f^Aj SJJ+/&Z
/?l/L-8-3
TYPE FACILITY
POINT OF EMISSIONS
Hr.
//
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STEAM PLUME
(check 1f applicable)
Attached
Detached
COMMENTS
B-28
-------
- /
RECORD OF VISUAL DETERMINATIN OF OPACITY
PAGE
OF
COMPANY /f/W/fj/
LOCATION -35 OU/ff^AJ . T£
TEST NO. AfL
C.+**
^T
*/
HOURS OF OBSERVATION /
OBSERVER
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OBSERVER CERTIFICATION DATE ^x// £ . ////
OBSERVER AFFILIATION /
7fe£* ' £»S>
POINT OF EMISSIONS fZ-**ves t«Jz.*/s t^ 4».Jt/J»
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/O
Time
Start-End
?/l- f/7
tt(. Readings ranged from O to /5" X opacl
The source was/was not In compliance with
at the time evaluation was made.
ty
-------
-------
COMPANY
LOCATION
TEST NO. ^C
DATE *»«/
OBSERVATION RECORD
OBSERVER
TYPE FACILITY
POINT OF EMISSIONS
PAGE _£ OF J_
;./
Hr.
09
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61
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B-30
-------
COMPANY
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE _3 OF
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TYPE FACILITY
POINT OF
Hr.
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-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE _ OF
w
w
ISJ
COMPANY */*,»**£
LOCATION OUc/or»V . S,C,
TEST NO. . AtJL&R
DATE £ V7 */
TYPE FACILITY /&.-.»* ^v^^^Vy
CONTROL DEVICE
CLOCK TIME
OBSERVER LOCATION
Distance to Discharge
Direction from Discharge
Height of Observation Point
BACKGROUND DESCRIPTION
WEATHER CONDITIONS
Wind Direction
Hind Speed
Ambient Temperature
SKY CONDITIONS (clear, over-
. cast. X clouds, etc.)
PLUME DESCRIPTION ****'
Color
Distance Visible
OTHER INFORMATION
y
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OBSERVER AFFILIATION
/% £»»,
POINT OF EMISSIONS /=£«.//,>*» .+ft.\/e +f 4~d/»*
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# Readings ranged from O to S X opacity
The source was/was not In compliance with
at the time evaluation was made.
-------
-------
OBSERVATION RECORD PAGE 2^ OF J
COMPANY /^U/»^ OBSERVER T^V &/£#*./
LOCATION £/AfJt$nA . "f'Li
TEST
DATE
Hr.
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6
TYPE FACILITY ^W,* fo/**^
POINT OF EMISSIONS /ZnSn,^ &&.*
STEAM PLUME
(check if applicable)
Attached
Detached
COMMENTS
T^oceyj D/x^J , J5stf/ji|
f
t.f**e#( £AA~s
B-33
-------
COMPANY -
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE 3 OF
TYPE FACILITY
POINT OF D1ISSIONS
%*/##*
Hr.
//
//
//
//
//
/I
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STEAM PLUME
(check 1f applicable)
Attached
Detached
COMMENTS
^/oieJ ***_
t~/ei*.J <^A
tf*st*e/ T*a^ Sites}
Opett^/ £*#<;
' i/ "
B-34
-------
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE / OF
COMPANY /I/^AV
LOCATION £/G&ey£*W . 5", f .
TEST NO. St&t. £ ft
DATE 4-/7'^
TYPE FACILITY JA^.*«, -%b/^*fa*
CONTROL DEVICE S£/
OBSERVER CERTIFICATION DATE V** >S/
OBSERVER AFFILIATION
?*Si* &ou.
POINT OF EMISSIONS f^Urrfoe* '*.-f*rt(t 4~S Att/et,)*
HEIGHT OF DISCHARGE POINT
Final
/a/-/
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^
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fa . Readings ranged from g? to /O X opacity
The source was/was not In compliance with
at the time evaluation was made.
-------
-------
COMPANY
LOCATION
TEST NO.
DATE
OBSERVATION RECORD
OBSERVER
PAGE
OF
TYPE FACILITY
POINT OF EMISSIONS
^
Hr.
Min.
Seconds
0 15 30 45
STEAM PLUME
(check 1f applicable)
Attached
Detached
COMMENTS
II
/
re
II
r?
O
r
s
5"
f)
r
O
0
o
o
O
0
O
A3
0
/x
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/7
£3
O
o
V
B-36
-------
COMPANY _
LOCATION
TEST NO.
DATE
Aft
OBSERVATION RECORD
OBSERVER
TYPE FACILITY
PAGE J£ OF
POINT OF PI I S S I ONS
> c
Hr.
/*
^
/I
A
/*-
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/J-
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0
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0
STEAM PLUME
(check 1f applicable)
Attached
Detached
COMMENTS
JtieJ cX£
/*&!/&*£*;&{ C+tof
r
»
B-37
-------
APPENDIX C
PROJECT PARTICIPANTS
C-l
-------
TABLE C-l. TEST TEAM PARTICIPANTS
Name
Affiliation
Function
Tom Clark
Dan Scheffel
Ed Monnig
PEDCo Environmental, Inc.
PEDCo Environmental, Inc.
TRW
Test Team
Test Team
Process Monitoring
C-2
-------
APPENDIX D
OBSERVER'S CERTIFICATION
D-l
-------
SOUTHWESTERN OHIO AIR POLLUTION CONTROL AGENCY
BOARD OF COMMISSIONERS
NORMAN A. MURDOCH
ROBERT A. TAFT II
ROBERT A. WOOD
MAIN OFFICE
2400 Beekman Street
Cincinnati, Ohio 45214
Phone: (513) 251-8777
LABORATORY
1675 Gest Street
Cincinnati, Ohio 45204
Phone: (513) 251-8863
MICHAEL J. MALONEY
Atmlniitntor
E. 0. ERMENC, P.E.
Aitl. Mmlnlttntor
April 23
Mr. Thomas R. Clark
PEDCo Environmental
11499 Chester Road
Cincinnati, Ohio 45246
Dear Mr. Clark:
APR 17 1981
PEDCO ENVIRONMENTAL
By _
On April 1 and 2, 1981, a "Smoke Emissions" field class
for the requalification of Air Pollution Control Officers
was conducted by the Southwestern Ohio Air Pollution Con-
trol Agency at the Millcreek Barrier Dam located off Gest
Street. The class was conducted and test papers graded
by Paul Fisher, Supervisor of Enforcement.
You were qualified at this session, along with the following
Thomas J. Wey
David R. Osterhart
Douglas J. Orf
George Beaujon
Sandra J. Howison
Philip J. Schworer
John Prohaska
Donald J. Loudin
Daniel E. Fitzgerald
Dan Scheffel
J. Thomas Bartke
Diane Albrinck
A grade of 37 or under is passing.
Next session will be conducted on October 6 and 7, 1981,
at the same location. Personnel from your agency are wel-
come to attend.
Sincerely ,
E . D. Ermenc , P.E. ,
Asst. County Admin., APCA
y '
Paul Fisher
Supervisor of Enforcement
EDE:PF:iv
D-2
-------
APPENDIX E
EPA TEST METHOD 9
E-l
-------
SUTBOD •—VISUAL BRBHUTAROir OS* TBB
OTAOTT or xsossiom rmox mim*ucr
BOUXCXS 10
Many stationary sources discharge visible
•missions into ths atmosphere; these •mis-'
•ions are usually in the shape of a plum*.
This method involves the determination of
plume opacity by qualified otieeivets. The
method includes procedures for ths training
and certification of observers, and procedures
to be used in the field for determination of
plume opacity. The appearance of a plume as
viewed by an observer depends upon a num-
ber of variables, some of which may be con-
trollable and some of which may not be
controllable in tbe field. Variables which can
be oontroll«d to an extent to which they BO
longer exert a significant influence upon
plume appearance include: Angle of the ob-
server with respect to the plume; angle of the
observer with respect to the sun; point of
observation of attached and detached steam
plume; and angle of the observer with re-
spect to a plume emitted from a rectangular
stack with a large length to width ratio. The
method Includes specific criteria applicable
to these variables.
Other variables which may not be control-
lable In tbe field are luminescence and color
contrast between the plume and tbe back-
ground against which tbe plume is viewed.
These variables exert an influence upon the
appearance of a plume as viewed by an ob-
server, and can affect the ability of the ob-
server to accurately assign opacity values
to the observed plume. Studies of the theory
of plume opacity and field studies have dem-
onstrated that a plume Is most visible and
presents tbe greatest apparent opacity when
viewed against a contrasting background. It
follows from this, and Is confirmed by field
trials, that the opacity of a plume, viewed
under conditions where a contrasting back-
ground U present cau be assigned with the
greatest degree of accuracy. However, tbe po-
tential for a positive error is also the greatest
when a plume Is viewed under such contrast-
Ing conditions. Under conditions presenting
a less contrasting background, the apparent
opacity of a plume ie less and approaches
rero as the color and luminescence contrast
decrease toward zero. As a result, significant
negative bias and negative errors can be
made when a plume Is viewed under lea*
contrasting conditions. A negative bias ds-
creases rather than Increases the possibility
that a plant operator will be cited for a vio-
lation of opacity standards due to observer
error.
Studies have been undertaken to determine
the magnitude of positive errors which can
be made by qualified observers while read-
ing plumes under contrasting conditions and
using the procedures set forth In this
method. The results of these studies (field
trials) which Involve a total of 769 sets of
95 readings each are as follows:
(1) For black plumes (133 sets at a smoke
generator). 100 percent of the sets were
read with a positive error » of lea.' than 7.6
percent .opacity; 99 percent were read with
a positive error of less than 5 percent opacity.
(3) For white plumes (170 sets at a smoke
generator, 168 seta at a coal-fired power plant,
998 sets at a sulfurle acid plant), 99 percent
of the sets were read with a positive error of
less than 7.5 percent opacity; 95 percent were
read with a positive error ofless than 5 per-
cent opacity.
Ths positive observational error associated
with an average of twenty-five readings Is
therefore established. The accuracy of- the
metbod must be taken Into account-when
determining possible violations of appli-
cable opacity standards.
' For a sst, positive •rrorsssverags opacity
determined by observers' 95 observations—
average opacity determined from transmls-
•ometer's 95 recordings.
I. Principle and appUaaMZtty.
l.f Principle. The opacity of emissions
from stationary sources to determined vis-
ually by a qualified observer. *
1J Applicability. This method to appli-
cable for the determination of the opacity
of emissions from stationery sourest pur-
suant to 160.11 (b) *nd for qualifying ob-
servers for visually determining opacity of
•missions.
a. Procedure*. The observer qualified la
accordance with paragraph 8 of this method
•haO use th* following procedures for vis-
ually determining the opacity of •missions:
9.1 Position,. The qualified observer shall
stand at a distance sufficient to provide a
clear view of the «»I«I««I«M with the sun
oriented in the 140* sector to his back. Con-
sistent with maintaining the above require-
ment, the observer shall, as much as possible.
make his observations from a position such
that his line of vision is approximately
perpendicular to the plume direction, and
when observing opacity of emissions from
rectangular outlets (e.g. roof monitors, open
baghousea, nonclrcular stacks), approxi-
mately perpendicular to the longer axis of
the outlet. The observer's line of sight should
not include more than one plume at a time
when multiple stacks are involved, and in
any case tbe observer should make his ob-
servations with hla line of sight perpendicu-
lar to tbe longer axis of such a set of multi-
ple stacks (e.g. stub stacks on baghouses).
9.9 Field records. The observer shall re-
cord the name of the plant, emission loca-
tion, type facility, observer's name and
affiliation, and the date on a field data sheet
(Figure 9-1). The time, estimated distance
to the emission location, approximate wind
direction, estimated wind speed, description
of the sky condition (presence and color of
clouds), and plume background are recorded
on a field data sheet at the time opacity read-
lags are initiated and completed.
9.3 Observations. Opacity observations
shall bo made at the point of greatest opacity
in that portion of the plume where con-
densed water vapor Is not present. The ob-
server shall not look continuously at tbe
plumr. but InsteixA shsl) observe tho plume
momentarily at 15-second intervals.
2.3.1 Attached steam plumes. When con-
densed water vapor is present within the
plume ss It emerge* from the emission out-
let, opacity observations shall be made be-
yond tbe point in the plume at which con-
densed water vapor Is no longer visible. The
observer shall record tbe approximate dis-
tance from the emission outlet to the point
in the plume at which the observations are
made.
332 Detached steam plume. When water
vapor in the plume condenses and becomes
visible at a distinct distance from the emis-
sion outlet, the opacity of emissions should
be evaluated at the emission outlet prior to
the condensation of water vapor and tbe for-
mation of tbe steam plume.
9.4 Recording observations. Opacity ob-
servations shall be recorded to the nearest 5
percent at la-second Intervals on an ob-
servational record sheet. (Bee Figure 9-9 for
an example.) A minimum of 94 observations
shall be recorded. Each momentary observa-
tion recorded shall bo deemed to represent
the average opacity of emissions for a 16-
seeond period.
9.5 Date Reduction. Opacity shall be de-
termined as an avenge of 94 consecutive
observations recorded at 15-second intervals.
Divide the observations recorded on the rec-
ord sheet into sets of 94 consecutive obser-
vations. A set is composed of any 94 con-
secutive observations. Bets need not be con-
secutive In time and-in no case shall two
seta overlap. For each set of 94 observations,
calculate the average by summing the opacity
of the 94 observations and dividing this cum
by 94. If an applicable standard specifies an
averaging tlms requiring more than 94 ob-
servations, calculate the average for all ob-
servations made during the specified time
period. Record the average opacity on a record
sheet. (See Figure 9-1 for an example.)
8. Qualification* and testing.
8.1 Certification requirements. To receive
certification as • qualified observer, a can-
didate must be tested and demonstrate the
ability to assign opacity readings in 5 percent
mcrementa to 95 different black plums* and
M different white plumes, with «a error
not to srassd 16 percent opacity OB aay one
res lime and an average error -not to sxceed
7.5 percent opacity In each category. Candi-
dates shall be tested according to the pro*
oadures described in paragraph 8.9. Smoke
generators used pursuant to paragraph 8.9
•hall be equipped with a smoke meter which
meets the requirements of paragraph S3. '
The certification shall be valid for a period
of 6 months, at which time the qualification
procedure must be repeated by any observer
In order to retain certification.
• 8.9 Certification procedure. The certifica-
tion test consists of showing the candidate a
complete run of 60 plumes—25 Mack plumes
and 95 white plumes generated by a smoke
generator. Plumes within each set of 96 black
and 25 white runs shall be presented in ran-
dom order. Tbe candidate assigns an opacity
value to each plume and records his obser-
vation on a suitable form. At the completion
of each run of 50 readings, the score of the
candidate Is determined. U a candidate fails
to qualify, the complete run of 50 readings
must be repeated in any retest. The smoke
test may be administered as part of a smoke
school or training program, and may be pre-
ceded by training or familiarization runs of
the smoke generator during which fyT""*1****
are shown black and white plumes of known
opacity.
• 93 Smoke generator specifications. Any
•moke generator used for the purposes of
paragraph 8.9 shall be equipped wHh a smoke
meter Installed to measure opacity across
the diameter of the smoke generator stack.
The smoke meter output shall display in-
stack opacity based upon a pathlength equal
to the Btecfc exit diameter, on a full 0 to 100
percent chart recorder scale. Tbe smoke
meter optical design and performance shall
meet the specifications shown in Table 9-1.
The smoke meter shall be calibrated as pre-
scribed in paragraph 8.3.1 prior to the con-
duct of each smoke reading test. A* the
completion of each test, the sero and span
drift shall be cuecked and if the drift ex-
ceeds *l percent opacity, the condition shall
be corrected prior to conducting any subse-
quent test runs. Tbe smoke meter shall bo
demonstrated, at tbe time of Installation, to
meot the specifications listed In Table 9-1.
This demonstration shall bo repeated fol-
lowing any subsequent repair or replacement
at the photocell or associated electronic cir-
cuitry including the chart recorder or output
meter, or •very 6 months, whichever occurs
first.
8.3.1 Calibration. Tit* smoke meter Is
calibrated after allowing a minimum of 80
minutes warmup by alternately producing
simulated opacity of 0 percent and 100 per-
cent. When stable response at 0 percent or
100 percent Is noted, the smoke meter ls ad-
lusted to produce an output of 0 percent or
100 percent, as appropriate. This calibration
shall be repeated until stable 0 percent and
100 percent reading! are produced without
adjustment. Simulated 0 percent and 100
percent opacity values may be produced by
alternately •witching the power to the light
source on and off while the smoke generator
is not producing smoke*
Ill-Appendix A-35
E-2
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TABU »-l—6MOKK MCTUl DESIGN AND
PCXrOBMANCr BPBCITICATIONS
Parameter:
». Light source
b. Spectral response
of photocell.
e. Angle of view
d. Angle of projec-
tion.
e. Calibration error.
f. Zero and span
drift.
g. Response time—
Specification
Incandescent lamp
operated at nominal
rated voltage.
Photoplc (daylight
spectral response of
the human eye—
reference 4.3).
IS*' TT"'"'"'" total
angle.
15* maximum total
angle.
±3 % opacity, maxi-
mum.
£1% opacity, 30
minutes.
£6 seconds.
8.3.2 Smoke meter evaluation. The smoke
meter deslfn and performance are to be
evaluated as follov.-s:
3.3.2.1 Light source. Verify from manu-
facturer's date and from voltage measure-
ments made at the lamp, as Installed, that
the lamp Ss operated within ±6 percent ol
the nominal rated voltage.
8.3.2.2 Spectral response of photocell.
Verify from manufacturer's date, that tie
photocell has a photoplc response; l.e, the
spectral sensitivity of the cell shall closely
approximate tr..> siandf.-J Rp«tr*l-lumlnor,.
Ity curve for phoMplc vision wtich Is refer-
ence*: In (b) or Table 9-1.
3.3.2.3 Angle of view. Check construction
geojrvftty to ensure tbttt the U>i^l «ngle aT
view of the smoke plume, as veen by the
photocell, does not excoad 15*. The total
angle of new may be calculated from: I=8
tan-* d/2L, where t—total angle of view;
d=the sum of the photocell diameter-f the
diameter of tte limiting aperture: and
L = the distance from the photocell to the
limiting aperture. The liTdtlng aperture Is
the point In the path between the photocell
and the smoke plume where the angle of
view is most restricted. In smoke generator
smoke meters this Is normally *n orifice
plate.
3.3.2.4 Angle of projection. Check con-
struction geometry to ensure that the total
angle of projection of the lamp OB the
•moke plume does not exceed 16*. The total
angle of protection may be calculated from:
^=3 tan-1 d/2L, where t= total angle of pro-
jection; d= the sum of the length of the
lamp filament -f* the diameter of the 1*^***"^
aperture: and L= the distance from the lamp
to the limiting aperture.
3.3.2.6 Calibration error. Using neutral-
density filters of known opacity, check the
error between the actual response and the
theoretical linear response of the smoke
meter. This check Is accomplished by first
calibrating the smoke meter according to
3.3.1 and then Inserting a series of three
neutral-density filters of nominal opacity of
20. 60. and 76 percent in the smote meter
pathlength. Filters callbarted within ±2 per-
cent shall be used. Care should be taken
when inserting the Alters to prevent stray
light from affecting the meter. Make a total
of five nonconsecutlve readings for each
filter. The maximum error on any one read-
ing shall be 3 percent opacity,
3.3.2.8 Zero and span drift. Determine
the zero and span drift by calibrating and
operating the smoke generator In a normal
manner over a 1-hour period. The drift is
measured by checking the zero and span at
the end of this period.
332.7 Response time. Determine the re-
sponse time by producng the series of five
simulated 0 percent and 100 percent opacity
values and observing the time required to
reach stable response. Opacity values of 0
percent and 100 percent may be simulated
by alternately switching the power to the
light source off and on while the smoke
generator Is not operating.
4. E?fcr;nees.
4.1 Air Pollution Control District Rules
and Regulations. Los Angeles County Air
Pollution Control District, Regulation IV.
Prohibitions, Rule 60.
42 Walsburd, Melvtn T-. Field Operations
and Enforcement Manual for Air, TJJS. Envi-
ronmental Protection Agency. Research Tri-
angle Park, N.C, AFTD-1100, August 1872.
pp. 4.1-4.36.
4*3 Condon, E. U., and Odiahaw, H, Hand-
boot of Physics, UcOraw-BUl Co.. N.T, N.T,
1068. Table 3.1, p. 6-62.
Ill-Appendix A-36
E-3
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COMPANY
LOCATION
TEST NUMBER.
DATE
TYPE FACILITY,.
CONTROL DEVICE
FIGURE 9-1
RECORD OF VISUAL DETERMINATION OF OPACITY
PAGE of
HOURS OF OBSERVATION.
OBSERVER
OBSERVER CERTIFICATION DATE.
OBSERVER AFFILIATION
POINT OF EMISSIONS
HEIGHT OP DISCHARGE POINT
w
i
13
T>
(D
3
a
H-
X
U)
CLOCK TIME
OBSERVER LOCATION
Distance to Discharge
Direction from Discharge
Height of Observation Point
BACKGROUND DESCRIPTION
WEATHER CONDITIONS
Wind Direction
Wind Speed
Ambient Temperature
SKY CONDITIONS (clear.
overcasti X clouds, etc.)
PLUME DESCRIPTION
Color
Distance Visible
OTHER INFQICtATIOtl
Initial
Final
SUMMARY OF AVERAGE OPACITY
Set
Number
T1mi»
Start— End
Opacity
Sum
Average
Readings ranged from
to % opacity
The source was/was not In compliance with
the time evaluation was made:
-------
FIGURE 9-2 OBSERVATION RECORD
PAGE
.OF
COMPANY
LOCATION
TEST NUMBGT
WTE
OBSERVER
TYPE FAC1LITV
POINT OF LM1SSMT
W
I
H
k
*
3
O.
H-
X
>
I
u>
00
Hr.
••«•••»
Hfn.
0
1
}
4
5
6
7
8
9
10
11
12
U
14
L^15
^16
17
18
19
20
21
22
23
24
25
26
27
28
29
0
^ Seconds
'15
30
45
STEAM PLUME
(check If applicable)
Attached
Detached
COMMENTS
FIGURE 9-2 0
(Cor
COMPANY
LOCATION
TEST
(ATE
Hr.
NUMBER
Mfn.
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
SO
51
52
53
54
55
56
57
58
"ft
Seconds
b
IS
i
30
1"
4b
(<*
At
SDoc.7*
OBSERVATION RECORD
PAGE OF_
OBSERVER ______
TYPE FAClLITV
POINT OF EHISSlBRT"
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